Building block and wall construction with grout-receiving lateral cells

ABSTRACT

An inclined pocket web extending longitudinally in upwardly diverging relation to a back wall of a building block, cooperates therewith to define one or more grout-receiving cells which are open at the front side of the block, each cell having its bottom area in the form of a pocket below the level of the front edge of the web. In a building wall embodying superimposed courses of the blocks, the open fronts present a plurality of acute edges of the pocket webs which function as screeding guides for accurately developing a flat planar face on the grout filling the cells.

United States Patent Lubin 1 51 Mar. 21, 1972 54 BUILDING BLOCK AND WALL 1,109,214 9/1914 Featherstone ..52/439 x CONSTRUCTION WITH GROUT- 1,265,447 5/ 1918 Havens ..52/505 RECEIVING LATERAL CELLS 2,514,536 7/1950 Burney ..52/607 2,819,495 l/l958 Krausz ..52/3 14 Edward H. Lubin, 10941 Strathmore, Apt. 56, Los Angeles, Calif. 90024 Filed: Jan. 14, 1970 Appl. No.: 2,788

Inventor:

US. Cl ..52/3l6, 52/367, 52/439, 52/505, 52/607, 52/444 Int. Cl ..E04b 2/32, E04c l/lO Field of Search ..52/444, 443, 606, 439, 607, 52/424, 379, 425, 608, 609, 378, 437, 438, 505

References Cited UNITED STATES PATENTS Primary Examiner-John E. Murtagh Attorney-Lynn H. Latta [57] ABSTRACT An inclined pocket web extending longitudinally in upwardly diverging relation to a back wall of a building block, cooperates therewith to define one or more grout-receiving cells which are open at the front side of the block, each cell having its bottom area in the form of a pocket below the level of the front edge of the web. In a building wall embodying superimposed courses of the blocks, the open fronts present a plurality of acute edges of the pocket webs which function as screeding guides for accurately developing a flat planar face on the grout filling the cells.

10 Claims, 8 Drawing Figures BUILDING BLOCK AND WALL CONSTRUCTION WITH GROUT-RECEIVING LATERAL CELLS BACKGROUND OF THE INVENTION I-Iollow concrete blocks, having ,cavities designed to be filled with grout in a wall in which the blocks have been assembled in superimposed courses, are in common usage and well known. Examples of U.S. patents illustrating such blocks and wall structures are Dochnal, U.S. Pat. No. 1,406,354 and Briscoe, U.S. Pat. No. 2,176,986. I am not aware of any such block, however, which presents an almost wholly open vertical side such that the grout filling the block cavities will provide substantially the entire area of one face of the wall constructed from the assembled blocks.

DESCRIPTION A general object of the invention is to provide a simplified wall construction and process utilizing a novel block that can be quickly and accurately placed, without requiring skill, and without mortar. Specific objects are to provide a block and process:

I. By which a skeleton wall can be completely erected by assembling the blocks in superimposed courses without mortar or grout, and grout subsequently applied to provide a monolithic wall structure and screeded to provide a substantially continuous grout surface as one face of the wall;

2. Permitting the installation of plumbing, electric wiring and other installations, as well as reinforcing steel, prior to grouting.

Other objects will become apparent in the following specifications and appended drawings, in which:

FIG. 1 is a plan view of a section of wall skeleton embodying the invention;

FIG. 2 is a front elevational view of the same, blocks of varied modified forms being shown in the respective courses;

FIG. 3 is an end elevational view of the same;

FIG. 4 is a plan view of an end block;

FIG. 5 is a front elevational view of the same;

FIG. 6 is a plan view of a corner block;

FIG. 7 is a front elevational view of the same; and

FIG. 8 is a perspective view of a block of the invention.

Referring now to the drawing in detail, and particularly to FIG. 8, I have shown therein, as an example of one form in which the invention may be embodied, a block which can be fabricated of concrete, other cementitious material, clay, or other suitable structural material; such block comprising, in general, a load-bearing back wall 10, a pair of load-bearing vertical cell webs l1 projecting forwardly from back wall 10 in positions spaced from one another and from the ends of the block, and a pocket web 12 extending diagonally upwardly and forwardly from the bottom of back wall 10 to which it is integrally joined. Web 12 is in three sections integrally joined to the sides of cell walls 11, a central section 13 bridging between the cell walls 1 l, and end sections 14 extending from the cell walls 11 to the respective ends of the block which is of a double-T formation in plan.

Grout-receiving cells (cavities) 1 5 are defined between the sections 13 and 14 of diagonal web 12 and the back wall 10 and cell walls 11. The bottom portion of each cell 15 is a pocket 16 lying below the level of the upper margin of the pocket web 12. Above this level, the cells 15 are open at the front of the skeleton wall to receive grout, and extend upwardly into the superimposed block, to the web 12 thereof. Thus the body of grout in each cell cavity, when solidified, provides a very strong integral tie between a respective pair of superimposed block sections. In the web sections 13 and 14 (FIG. 8) are a hole 17 and half holes, the latter matching the half holes of end-to-end abutting blocks in a wall course to define holes 18 between the abutting ends of the blocks. In the upper and lower ends of cell walls I] are respective half holes which match similar half holes in the cell walls of blocks in courses above and below to define horizontally aligned holes 19 (FIGS. 3 and 8) between grout cells 15. Holes 17, 18 are utilized to receive vertical reinforcing rods, electric conduit, plumbing pipes, etc., in a skeleton wall prior to grouting. Similarly, holes 19 function to receive horizontal reinforcing, electrical and plumbing lines, etc. Holes l7, 18 also function as drains for trapped air and water.

Web 12 has a free forward edge 21 defined by the intersection of bevelled upper faces 22 with the under faces of the web. Cell webs 11 have vertical forward edges 23 defined between equilateral double bevels 24. The edges 21 and 23 are of substantial acuteness, and lie in a common vertical plane to cooperatively provide a trowelling and/or screeding guide lattice by which an accurately flat and plumb wall face in which the edges 21 and 23 are substantially embedded and unnoticeable, can be developed at the surface of a body of grout 25 filling the pockets 15.

At the top of the block, the vertical cell walls 11 project above the load-bearing wall 10 to define interlock notches 30. Corresponding notches 31 are formed in the upper forward comers of cell walls. At the bottom of the block, wall 10 has a downwardly projecting margin 32 receivable in the notches 30 of a block on which it is superimposed, and the lower forward corners of cell walls 11 are provided with downwardly projecting lugs 33 which are receivable in notches 31. Thus the tops of the blocks of each course are interlocked with the bottoms of the blocks of a superimposed course so as to couple the courses together in a skeleton wall in which the load-bearing walls 10 lie in a common vertical plane to define a closed rear skin of the wall skeleton and the edges 21 and 23 of web 12 and cell walls 11 lie in a common vertical plane in which the inner face of the wall may be developed by screeding and/or trowelling. The horizontal transverse grout tie thus provided can be supplemented by an interlock (FIG. 1) between a vertical tongue 34 on the end of a bearing wall 10 and a vertical notch 35 in the opposed end of the wall 10 of an adjoining block. These interlocks not only provide for vertical block front alignment, but also provide a moisture and grout seepage barrier next to the rear surface of the wall, defined by bearing walls 10. The word rear," as used in this context, is intended to refer simply to the closed side of the block, the open, groutreceiving side being referred to as the front" side. It will be understood that either side may become the exterior side of the constructed wall, the other side being the interior.

In the upper rear margin of bearing wall 10 is a longitudinal groove 35 which, in the assembled wall, provides a simulated horizontal mortar joint for calking and pointing, conceals vertical alignment inaccuracies, conceals the cold joint, and forms a drip at the cold joint. In the rear vertical corner of one end of load-bearing wall 10 is a vertical groove 36 (FIG. 7) defining a simulated vertical mortar joint, providing for caulking or pointing and concealing the cold joint.

Diagonal web 12 functions to collect and hold most of the grout with which the cells 15 are filled. It is located for minimum first course bottom cell fill.

In erecting a wall, the blocks may be stacked against a temporary backing of plywood or other material which is removed after the wall has been grouted. Such backing is arranged to engage the bearing walls 10, leaving the cells open at the front of the wall skeleton, defined by acreeding edges 21, 23.

Reinforcing rods, electric conduit, plumbing, etc., are then installed through openings l7, l8, 19. Finally, grout is injected into cells 15, 16 by means of a gun, a trowel or other suitable means. A low-slump grout is used, such that the grout in the cells above the upper margin of diagonal web 12 will remain in fixed position after screeding or trowelling. The portions received in the pocket 16 are positively retained against movement, and retention of the upper portions is assisted by locking them into the holes l7, 18, 19 in webs l2 and 11.

The block of FIG. 8 is shown in the lower three courses in FIGS. 2 and 3. The web 12 in this block is of relatively simple design, with flat faces and cylindrical holes. In the fourth course from the bottom, there is shown a block with a web 40 of modified design, in which the faces are stepped to provide more secure retention of the grout. In the top course there is shown a block of another modified design wherein the web holes 41 and cell wall holes 42 are of double bevelled form. The bevels of these holes function: (1) to promote freer flow of grout between adjacent cells; (2) to minimize the area of contact between reinforcing rods and blocks; and (3) to improve and strengthen the interlocking ties between adjoining blocks.

FIGS. 4 and 5 show an end block (half as long as the block of FIG. 8) wherein an imperforate end wall 45 is disposed in opposed parallel relation to a single cell wall 11, spaced therefrom at a distance such that its end face and the open opposite end of the block are equidistant from the cell wall 11. In its diagonal web 12 is an opening 117 corresponding in function to openings 17 of the main blocks. FIGS. 6 and 7 disclose a corner block embodying an arm 50 of full block length and an arm 51 of half block length. In the corner joining the arms 50 and 51 is a mitred cell wall 52 having top and bottom recesses cooperating in superimposed blocks to define corner holes 119. Otherwise, each of the arms 50, 51 embody parts corresponding to the parts in the block of FIG. 8, and designated by the same numerals.

Iclaim:

l. A wall structure comprising a plurality of blocks arranged end to end in a plurality of horizontal courses superimposed one upon another, each of said blocks comprising:

a bearing wall extending longitudinally in a vertical plane to define a closed vertical back side of the block;

a cell web integrally joined to said bearing wall in a vertical plane and projecting forwardly therefrom, said cell web being substantially coextensive with said bearing wall in height;

and a pocket web integrally joined to the lower margin of said bearing wall and projecting diagonally forwardly and upwardly from said lower margin to define therewith a grout-holding pocket;

said superimposed courses collectively defining a skeleton wall having a closed rear vertical skin composed of the bearing walls of the assembled blocks and having a plurality of grout-receiving cells, open at the top of each block and at the forward side of said skeleton wall and defined between vertically spaced pocket webs and horizontally spaced cell webs and said closed rear skin of said skeleton wall;

and bodies of grout contained in and bridging between the cells of the assembled blocks and joining the blocks together in a solid block wall;

said pockets constituting the bottom portions of said cells and functioning to retain in said cells the grout inserted therein after erection of said skeleton wall.

2. A building wall as defined in claim 1, wherein said cell web and pocket web are provided with holes through which reinforcing rods, plumbing and electrical conduit can be installed in said skeleton wall prior to grouting, and through which the bodies of grout filling adjacent cells will be joined by integral ties of grout material.

3. A building wall as defined in claim 1, wherein said bearing wall has in one of its longitudinal margins a groove adapted to provide a simulated horizontal mortar joint in the back face of the completed wall, providing for caulking and pointing, concealing vertical alignment inaccuracies and the cold joints of the skeleton wall, and providing a drip at said cold joints.

4. A wall as defined in claim 1, wherein said pocket web has flat upper and lower faces.

5. A building block comprising:

a bearing wall extending longitudinally to define a vertical back side of the block as assembled in a wall;

a cell web integrally joined to said bearing wall and projecting forwardly therefrom, said cell web being substantially coextensive with said bearing wall in height;

and a pocket web integrally joined to the lower margin of said bearing wall and projecting diagonally forwardly and upwardly therefrom and defining therewith a grout-holding pocket;

said block being adapted to be assembled along with other like blocks in a plurality of superimposed courses collectively defining a skeleton wall having a plurality of groutreceiving cells, open at the forward side of said wall, defined between vertically spaced pocket webs and horizontally spaced cell webs of said wall, said pockets constituting the bottom portions of said cells and functioning to retain in said cells the grout inserted therein after erection of said skeleton wall;

said cell web and pocket web having respective bevelled forward margins terminating in narrow edges disposed in a common vertical plane in said skeleton wall and functioning as a screeding and trowelling guide lattice which can be substantially embedded and unnoticeable in the screeded or troweled surface of the finished wall.

6. A building block comprising:

a bearing wall extending longitudinally to define a vertical back side of the block as assembled in a wall;

a cell web integrally joined to said bearing wall and projecting forwardly therefrom, said cell web being substantially coextensive with said bearing wall in height;

and a pocket web integrally joined to the lower margin of said bearing wall and projecting diagonally forwardly and upwardly therefrom and defining therewith a grout-holding pocket;

said block being adapted to be assembled along with other like blocks in a plurality of superimposed courses collectively defining a skeleton wall having a plurality of groutreceiving cells, open at the forward side of said wall, defined between vertically spaced pocket webs and horizontally spaced cell webs of said wall, said pockets constituting the bottom portions of said cells and functioning to retain in said cells the grout inserted therein after erection of said skeleton wall;

said cell web having respective ends, one provided with a shallow recess and the other with a low projection receivable in said recess with a mating action to provide an interlock for locking superimposed blocks together with their back faces in a common vertical plane in said skeleton wall.

7. A building block comprising:

a bearing wall extending longitudinally to define a vertical back side of the block as assembled in a wall;

a cell web integrally joined to said bearing wall and projecting forwardly therefrom, said cell web being substantially coextensive with said bearing wall in height;

and a pocket web integrally joined to the lower margin of said bearing wall and projecting diagonally forwardly and upwardly therefrom and defining therewith a grout-holding pocket;

said block being adapted to be assembled along with other like blocks in a plurality of superimposed courses collectively defining a skeleton wall having a plurality of groutreceiving cells, open at the forward side of said wall, defined between vertically spaced pocket webs and horizontally spaced cell webs of said wall, said pockets constituting the bottom portions of said cells and functioning to retain in said cells the grout inserted therein after erection of said skeleton wall;

said bearing wall having in one end a vertical tongue and in its other end a vertical notch adapted to receive said tongue to provide a transverse interlock effecting a moisture barrier between adjoining bearing walls.

8. A building block comprising:

a bearing wall extending longitudinally to define a vertical back side of the block as assembled in a wall;

a cell web integrally joined to said bearing wall and projecting forwardly therefrom, said cell web being substantially coextensive with said bearing wall in height;

and a pocket web integrally joined to the lower margin of said bearing wall and projecting diagonally forwardly and upwardly therefrom and defining therewith a grout-holding pocket;

said block being adapted to be assembled along with other like blocks in a plurality of superimposed courses collectively defining a skeleton wall having a plurality of groutreceiving cells, open at the forward side of said wall, defined between vertically spaced pocket webs and horizontally spaced cell webs of said wall, said pockets constituting the bottom portions of said cells and functioning to retain in said cells the grout inserted therein after erection of said skeleton wall;

said block being of double-T formation in plan, there being two of said cell webs spaced longitudinally from one another and from the ends of the block so as to define one complete pocket at the center of the block and half pockets at the respective ends of the block, said pocket web including corresponding central and end sections, the latter having half holes formed in their ends.

9. A building block comprising:

a bearing wall extending longitudinally to define a vertical back side of the block as assembled in a wall;

a cell web integrally joined to said bearing wall and projecting forwardly therefrom, said cell web being substantially coextensive with said bearing wall in height;

and a pocket web integrally joined to the lower margin of said bearing wall and projecting diagonally forwardly and upwardly therefrom and defining therewith a grout-holding pocket;

said block being adapted to be assembled along with other like blocks in a plurality of superimposed courses collectively defining a skeleton wall having a plurality of groutreceiving cells, open at the forward side of said wall, defined between vertically spaced pocket webs and horizontally spaced cell webs of said wall, said pockets constituting the bottom portions of said cells and functioning to retain in said cells the grout inserted therein after erection of said skeleton wall;

said pocket web having stepped upper and lower faces defining longitudinally extending horizontal and vertical surfaces interlocking with the grout filling said cells in the completed wall.

10. A building block comprising:

a bearing wall extending longitudinally to define a vertical back side of the block as assembled in a wall;

a cell web integrally joined to said bearing wall and projecting forwardly therefrom, said cell web being substantially coextensive with said bearing wall in height;

and a pocket web integrally joined to the lower margin of said bearing wall and projecting diagonally forwardly and upwardly therefrom and defining therewith a grout-holding pocket;

said block being adapted to be assembled along with other like blocks in a plurality of superimposed courses collectively defining a skeleton wall having a plurality of groutreceiving cells, open at the forward side of said wall, defined between vertically spaced pocket webs and horizontally spaced cell webs of said wall, said pockets constituting the bottom portions of said cells and functioning to retain in said cells the grout inserted therein after erection of said skeleton wall;

said cell web and pocket web being provided with respective holes and having intersecting double bevels defining at least some of said holes, through which reinforcing rods, plumbing and electrical conduits can be installed in said skeleton wall prior to grouting, and through which the bodies of grout filling adjacent cells will be joined by integral ties of grout material. 

1. A wall structure comprising a plurality of blocks arranged end to end in a plurality of horizontal courses superimposed one upon another, each of said blocks comprising: a bearing wall extending longitudinally in a vertical plane to define a closed vertical back side of the block; a cell web integrally joined to said bearing wall in a vertical plane and projecting forwardly therefrom, said cell web being substantially coextensive with said bearing wall in height; and a pocket web integrally joined to the lower margin of said bearing wall and projecting diagonally forwardly and upwardly from said lower margin to define therewith a grout-holding pocket; said superimposed courses collectively defining a skeleton wall having a closed rear vertical skin composed of the bearing walls of the assembled blocks and having a plurality of groutreceiving cells, open at the top of each block and at the forward side of said skeleton wall and defined between vertically spaced pocket webs and horizontally spaced cell webs and said closed rear skin of said skeleton wall; and bodies of grout contained in and bridging between the cells of the assembled blocks and joining the blocks togetheR in a solid block wall; said pockets constituting the bottom portions of said cells and functioning to retain in said cells the grout inserted therein after erection of said skeleton wall.
 2. A building wall as defined in claim 1, wherein said cell web and pocket web are provided with holes through which reinforcing rods, plumbing and electrical conduit can be installed in said skeleton wall prior to grouting, and through which the bodies of grout filling adjacent cells will be joined by integral ties of grout material.
 3. A building wall as defined in claim 1, wherein said bearing wall has in one of its longitudinal margins a groove adapted to provide a simulated horizontal mortar joint in the back face of the completed wall, providing for caulking and pointing, concealing vertical alignment inaccuracies and the cold joints of the skeleton wall, and providing a drip at said cold joints.
 4. A wall as defined in claim 1, wherein said pocket web has flat upper and lower faces.
 5. A building block comprising: a bearing wall extending longitudinally to define a vertical back side of the block as assembled in a wall; a cell web integrally joined to said bearing wall and projecting forwardly therefrom, said cell web being substantially coextensive with said bearing wall in height; and a pocket web integrally joined to the lower margin of said bearing wall and projecting diagonally forwardly and upwardly therefrom and defining therewith a grout-holding pocket; said block being adapted to be assembled along with other like blocks in a plurality of superimposed courses collectively defining a skeleton wall having a plurality of grout-receiving cells, open at the forward side of said wall, defined between vertically spaced pocket webs and horizontally spaced cell webs of said wall, said pockets constituting the bottom portions of said cells and functioning to retain in said cells the grout inserted therein after erection of said skeleton wall; said cell web and pocket web having respective bevelled forward margins terminating in narrow edges disposed in a common vertical plane in said skeleton wall and functioning as a screeding and trowelling guide lattice which can be substantially embedded and unnoticeable in the screeded or troweled surface of the finished wall.
 6. A building block comprising: a bearing wall extending longitudinally to define a vertical back side of the block as assembled in a wall; a cell web integrally joined to said bearing wall and projecting forwardly therefrom, said cell web being substantially coextensive with said bearing wall in height; and a pocket web integrally joined to the lower margin of said bearing wall and projecting diagonally forwardly and upwardly therefrom and defining therewith a grout-holding pocket; said block being adapted to be assembled along with other like blocks in a plurality of superimposed courses collectively defining a skeleton wall having a plurality of grout-receiving cells, open at the forward side of said wall, defined between vertically spaced pocket webs and horizontally spaced cell webs of said wall, said pockets constituting the bottom portions of said cells and functioning to retain in said cells the grout inserted therein after erection of said skeleton wall; said cell web having respective ends, one provided with a shallow recess and the other with a low projection receivable in said recess with a mating action to provide an interlock for locking superimposed blocks together with their back faces in a common vertical plane in said skeleton wall.
 7. A building block comprising: a bearing wall extending longitudinally to define a vertical back side of the block as assembled in a wall; a cell web integrally joined to said bearing wall and projecting forwardly therefrom, said cell web being substantially coextensive with said bearing wall in height; and a pocket web integrally joined to the lower margin of said bearing wall and projectiNg diagonally forwardly and upwardly therefrom and defining therewith a grout-holding pocket; said block being adapted to be assembled along with other like blocks in a plurality of superimposed courses collectively defining a skeleton wall having a plurality of grout-receiving cells, open at the forward side of said wall, defined between vertically spaced pocket webs and horizontally spaced cell webs of said wall, said pockets constituting the bottom portions of said cells and functioning to retain in said cells the grout inserted therein after erection of said skeleton wall; said bearing wall having in one end a vertical tongue and in its other end a vertical notch adapted to receive said tongue to provide a transverse interlock effecting a moisture barrier between adjoining bearing walls.
 8. A building block comprising: a bearing wall extending longitudinally to define a vertical back side of the block as assembled in a wall; a cell web integrally joined to said bearing wall and projecting forwardly therefrom, said cell web being substantially coextensive with said bearing wall in height; and a pocket web integrally joined to the lower margin of said bearing wall and projecting diagonally forwardly and upwardly therefrom and defining therewith a grout-holding pocket; said block being adapted to be assembled along with other like blocks in a plurality of superimposed courses collectively defining a skeleton wall having a plurality of grout-receiving cells, open at the forward side of said wall, defined between vertically spaced pocket webs and horizontally spaced cell webs of said wall, said pockets constituting the bottom portions of said cells and functioning to retain in said cells the grout inserted therein after erection of said skeleton wall; said block being of double-T formation in plan, there being two of said cell webs spaced longitudinally from one another and from the ends of the block so as to define one complete pocket at the center of the block and half pockets at the respective ends of the block, said pocket web including corresponding central and end sections, the latter having half holes formed in their ends.
 9. A building block comprising: a bearing wall extending longitudinally to define a vertical back side of the block as assembled in a wall; a cell web integrally joined to said bearing wall and projecting forwardly therefrom, said cell web being substantially coextensive with said bearing wall in height; and a pocket web integrally joined to the lower margin of said bearing wall and projecting diagonally forwardly and upwardly therefrom and defining therewith a grout-holding pocket; said block being adapted to be assembled along with other like blocks in a plurality of superimposed courses collectively defining a skeleton wall having a plurality of grout-receiving cells, open at the forward side of said wall, defined between vertically spaced pocket webs and horizontally spaced cell webs of said wall, said pockets constituting the bottom portions of said cells and functioning to retain in said cells the grout inserted therein after erection of said skeleton wall; said pocket web having stepped upper and lower faces defining longitudinally extending horizontal and vertical surfaces interlocking with the grout filling said cells in the completed wall.
 10. A building block comprising: a bearing wall extending longitudinally to define a vertical back side of the block as assembled in a wall; a cell web integrally joined to said bearing wall and projecting forwardly therefrom, said cell web being substantially coextensive with said bearing wall in height; and a pocket web integrally joined to the lower margin of said bearing wall and projecting diagonally forwardly and upwardly therefrom and defining therewith a grout-holding pocket; said block being adapted to be assembled along with other like blocks in a plurality of superimposed courses collectively defining a skeleton wall having a plurality of grout-receiving cells, open at the forward side of said wall, defined between vertically spaced pocket webs and horizontally spaced cell webs of said wall, said pockets constituting the bottom portions of said cells and functioning to retain in said cells the grout inserted therein after erection of said skeleton wall; said cell web and pocket web being provided with respective holes and having intersecting double bevels defining at least some of said holes, through which reinforcing rods, plumbing and electrical conduits can be installed in said skeleton wall prior to grouting, and through which the bodies of grout filling adjacent cells will be joined by integral ties of grout material. 